Wind Turbine Blade Embedding Element Moulding

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Solution Overview

Problem

Existing embedding elements for wind turbine rotor blades suffer from insufficient pull-out resistance of bushings at the root end, leading to potential failure of the connection between the blade and the hub, and result in significant waste during machining.

Innovation Solution

A method of manufacturing embedding elements using a moulding process with movable core members, where fibre material and a binding agent are compacted and heated to form a preform, which is then cooled and released, reducing waste and enhancing structural strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional machining methods are used to manufacture embedding elements, then manufacturing precision can be achieved, but waste production increases significantly (15-30% of total mass)

Engineering Contradiction:

Improveembedding element precisionVSAvoidwaste production

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The patent replaces traditional mechanical machining processes with a moulding process that directly forms the embedding element. Instead of machining away material to achieve the desired shape, the element is formed by compacting fibre material and binding agent in a mould cavity, eliminating the need for subsequent machining operations and the associated waste.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the manufacturing approach from subtractive machining to additive moulding. By controlling parameters such as compaction pressure, temperature, and material composition during the moulding process, the desired precision and geometry are achieved directly without material removal, thus eliminating waste production.

Inventive Principle:

Principle #35Parameter changes

2Force

If the number of bushings is increased to handle heavy loads, then load transfer capability improves, but the remaining composite material area between bushings is reduced, leading to insufficient support and potential pull-out failure

Engineering Contradiction:

Improveload transfer capabilityVSAvoidbushing retention

Core Design Contradiction:

ForceVSReliability

Solution Approach 1:

The patent uses composite materials consisting of fibre reinforcement and binding agent to create embedding elements with enhanced mechanical properties. These composite elements provide superior structural support between bushings, maintaining adequate composite material area even when bushing density is increased, thereby preventing pull-out failure while enabling heavy load transfer.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The embedding elements are designed with curved or contoured surfaces that conform to the cylindrical shape of adjacent bushings. This curvature creates optimal contact surfaces and distributes loads more effectively, enhancing both the load transfer capability and the retention of bushings within the composite structure.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Strength

If embedding elements are manufactured with high structural strength, then pull-out resistance improves, but the elements may become too rigid and cause wrinkle formation in the shell fibre material

Engineering Contradiction:

Improvepull-out resistanceVSAvoidwrinkle formation

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent employs fibre materials and binding agents that create embedding elements with flexible, conformable surfaces. These surfaces can adapt to the surrounding shell fibre material during blade manufacturing, preventing wrinkle formation while maintaining sufficient structural strength for pull-out resistance through optimized fibre orientation and composite composition.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The embedding elements exhibit local variations in material properties, with higher strength and stiffness in regions requiring load bearing and pull-out resistance, while maintaining flexibility and conformability in regions that contact the shell fibre material. This localized quality optimization resolves the contradiction between strength and flexibility.

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method results in embedding elements with improved pull-out resistance, reduced wrinkle formation, and a 15-30% reduction in waste compared to traditional machining methods, while maintaining a flexible and soft structure suitable for the root end of the blade.

Implementation Method 1

heating the fibre material and the binding agent to form the embedding element or a preform

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

cooling the embedding element or the preform

Methodology Applied

Scientific EffectCooling: Cooling

Data Source

PatentUS20250114985A1Manufacturing of an embedding element for a wind turbine blade

Publication Date: 2025.04.10 LM WIND POWER AS

AI summary

A method of manufacturing an embedding element (76) for embedment in a shell structure of a wind turbine rotor blade (10) is provided, wherein the method comprises arranging a fibre material (99) and a binding agent on the lower mould plate (93) in between the first movable core member (97) and the second movable core member (98). One or both of the core members can be pushed towards the cavity for compacting the fibre material (99), which is then heated together with the binding agent to form the embedding element (76) or a preform (90) thereof.